18.

STARTING SYSTEM Bet & Win 125/150

18
__________________________________________________________________________________

__________________________________________________________________________________

__________________________________________________________________________________

18
__________________________________________________________________________________

__________________________________________________________________________________

STARTING SYSTEM
__________________________________________________________________________________

STARTING SYSTEM LAYOUT -------------------------------------- 18-1

SERVICE INFORMATION -------------------------------------------- 18-2
TROUBLESHOOTING ------------------------------------------------- 18-2
STARTER MOTOR ----------------------------------------------------- 18-3
STARTER CLUTCH INSPECTION----------------------------------- 18-5
STARTER RELAY INSPECTION ------------------------------------ 18-6

18-0
18. STARTING SYSTEM Bet & Win 125/150

STARTING SYSTEM LAYOUT

Stop Switches

Starter Relay

Starter Button

Starter Motor

STARTING CIRCUIT

18-1
18. STARTING SYSTEM Bet & Win 125/150

SERVICE INFORMATION
GENERAL INSTRUCTIONS
• The removal of starter motor can be accomplished with the engine installed.
• For the starter clutch removal, refer to page 10-3.
• After the starter clutch is installed, be sure to add the engine oil and coolant and then bleed air
from the cooling system.

SPECIFICATIONS
Item Standard (mm) Service Limit (mm)
Starter motor brush length 12.5mm 8.5mm

TORQUE VALUES
Starter motor mounting bolt 6.7_ 10.8N-m
Starter motor case screw 2.9_ 4.9N-m
Starter clutch bolt 9.8_ 13.7N-m

SPECIAL TOOLS
Flywheel holder
Flywheel puller

TROUBLESHOOTING

Starter motor won‘t turn Lack of power

• Fuse burned out • Weak battery
• Weak battery • Loose wire or connection
• Faulty ignition switch • Foreign matter stuck in starter motor
• Faulty starter clutch or gear
• Faulty front or rear stop switch
• Faulty starter relay Starter motor rotates but engine does
• Poorly connected, broken or shorted wire not start
• Faulty starter motor • Faulty starter pinion
• Starter motor rotates reversely
• Weak battery

18-2
18. STARTING SYSTEM Bet & Win 125/150

STARTER MOTOR
REMOVAL
＊ • Before removing the starter motor, turn
the ignition switch OFF and remove
the battery ground. Then, turn on the
ignition switch and push the starter
button to see if the starter motor
operates properly.

Starter Motor Cable

Remove the seat, met-in box and frame center
cover. (!2-3) Motor Case
Remove the waterproof rubber jacket and
disconnect the starter motor cable.
Remove the two starter motor mounting bolts
and the motor.

DISASSEMBLY
Remove the two starter motor case screws,
front cover, rear cover, motor case and other
parts.

Case Screws Front Cover

Commutator
INSPECTION
Inspect the removed parts for wear, damage
or discoloration. Replace if necessary.
Clean the commutator if there is metal
powder between the segments.

Check for continuity between pairs of the

commutator segments and there should be
continuity.
Also, make a continuity check between
individual commutator segments and the
armature shaft. There should be no
continuity.

18-3
18. STARTING SYSTEM Bet & Win 125/150

STARTER MOTOR CASE CONTINUITY

CHECK
Check to confirm that there is no continuity
between the starter motor wire terminal and
the motor front cover.
Also check for the continuity between the
wire terminal and each brush.
Replace if necessary.

Wire Terminal

Measure the length of the brushes.

Service Limit: 8.5mm replace if below

Check for continuity between the brushes. If

there is continuity, replace with new ones.

Check if the needle bearing in the front cover Bushing

turns freely and has no excessive play.
Replace if necessary.
Check the dust seal for wear or damage.

Dust Seal

18-4
18. STARTING SYSTEM Bet & Win 125/150

ASSEMBLY
Apply grease to the dust seal in the front
cover.
Install the brushes onto the brush holders.
Apply a thin coat of grease to the two ends
of the armature shaft.
Insert the commutator into the front cover.

Front Cover
Tab Groove O-ring
Install a new O-ring to the front cover.
Install the starter motor case, aligning the tab
on the motor case with the groove on the
front cover.
Tighten the starter motor case screws.

Motor Case
O-ring Starter Motor Cable
INSTALLATION
Connect the starter motor cable.
Check the O-ring for wear or damage and
replace if necessary.
Apply grease to the O-ring and install it to
the starter motor.
Tighten the two mounting bolts.

STARTER CLUTCH INSPECTION

Refer to pages 10-4 and 10-5 for the starter
clutch removal, inspection and installation.

18-5
18. STARTING SYSTEM Bet & Win 125/150

STARTER RELAY INSPECTION

Disconnect the starter relay wire connector.
Check for continuity between the yellow/red
wire terminal and ground.
There should be continuity when the starter
button is depressed.
If there is no continuity, check the starter
button for continuity and inspect the wire.

Yellow/Red Wire
Starter Relay
OPERATION TEST
Connect the electric tester to the starter relay
larger terminals that connect to the battery
positive cable and the starter motor cable.
Connect a fully charged battery across the
starter relay yellow/red and green/yellow wire
terminals.
Check for continuity between the starter
relay large terminals. The relay is normal if
there is continuity.

18-6